Tire mold and method of making the same



. 15, 1936. R. BATEMAN 3 TIRE MOLD AND METHOD OF MAKING THE SAME Filed April 21, 1934 4 Sheets-Sheet l v 80 .m. 75 Q; 'L 23 h g Y gvwwwtovs i Z6 $240k cademan &

Dec. 15, 1 936. I Q BATEMAN 2,064,778

I TIRE IMOLDAND METHbD OF MAKING THE SAME Filed April 21, 1934 4 Sheets-Sheet 2 15, 1936. R m-EMAN 2,064,778

TIRE MOLD AND METHOD OF MAKING THE SAME Filed April 21, 1954 4Sheets-Sheet3 R. c. BATEMAN 2,064,778

TIRE MOLD AND METHOD OF MAKING THE SAME v Dec. 15, 1936.

Filed April 21, 1934 4 Sheets-fieet 4 Patented Dec. 15, 1936 UNITED STATES PATENT OFFICE.

Ralph C. Bateman, Akron, Ohio, assignor to Wingfoot Corporation, Wilmington, Del., a corporation of Delaware Application April 21, 1934, Serial No. 721,793

4 Claims. (01. 204-8) This invention relates to an improved, less stantial variation in the electric potential. A costly mold of the type used in shaping rubber second contact ring may be clamped to the outer motor vehicle tires, and to a method and appaedge of the matrix to distribute the current with ratus for economically producing such molds or still greater evenness. Other means capable of other similar articles. More particularly the in supplying current to substantially the entire cirvention concerns a tire mold comprised of a cumference of the matrix may be substituted. heavy cast frame and a molding face consisting During plating the matrix is suspended in a at least in part of an electroformed shell, rigidly horizontal position where plating proceeds equalmounted in the frame. The shell, which is prefly and simultaneously over the entire surface 10 erably ofnickel, may be made large enough to without the necessity of a great quantity of platl0 form'the complete molding face but usually only ing solution or of continuous rotation of the maserves to mold the tread section of the. tire. In trix. Every precaution is taken to remove foreign the latter case the side walls of the tire are moldmaterial from the plating tank. Both the anodes ed directly by the cast mold frame which is maand the cathode matrix are surrounded by porous l5 chined to the necessary configuration. The inbags and the solution is filtered before use and vention includes the electroformed shell, particucontinuously during plating. larly a nickel shell, and method and apparatus The plating bath may be of the usual type, but for forming the same, and also a treated rubber preferably is a bath, far exceeding in nickel concathode suitable for use in the manufacture of centration' the baths heretofore used. With a -2 such ashell or a great variety of other objects, high concentration of nickel in the bath, control 2 particularly objects having irregular surfaces. of the bath composition has been found to be The production of tire molds by the usual greatly simplifiedand much higher current densimethod is accomplished only with considerable ties may be used with the surprising result of indifliculty occasioned by the great amount and creased throwing power and ductile, uniform decomplexity of the engraving necessary to form posits in the grooves as well as upon the raised 25 the tread design upon the face thereof. Accordportions of the matrix. Hydrogen peroxide ing to the present invention, however, the neceswhich prevents brittle deposits is contained in the sity for this engraving is eliminated and accurate bath in a quantity closely controlled by use of molds are produced simply and economically. a new indicator and the acidity of the bath is "o In general the new method comprises forming likewise controlled and adjusted at frequent ina metallic shell by electroplating a rubber matrix tervals. United States; patent applications by of the shape of one half of the tread of a tire, Fred K. Bezzenberger, Serial No. 703,247, and by the half being obtained by dividing the tread Fred K. Bezzenberger and Ralph C. Bateman along a circumferentially extending medial line. Serial No. 703,246 were filed on December 20, 1933 5 The electroformed shell so obtained is mounted and relate to the general application of the new in a mold frame and sealed in place with babbitt bath composition, its control, and processes of or some'other soft metal. using it for the electrodeposition of nickel. The

A number of outstanding features of novelty present application is in part a continuation of characterize the improved application of this application 703,246 as to so much of the present 40 general method. The rubber matrix, stretched invention asis described therein. 40

slightly upon a form to compensate for the These features of novelty as well as many othshrinkage which has occurred during its vulcaners including the method of mounting the. elecization, is metallized, preferably by spraying with trodeposited shell in the tire mold frame will be a bronze or copper lacquer, and is subsequently explained in detail by describing the example dipped into an alkaline cyanide solution to silver shown in the accompanying drawings in which: 45

the surface and thus improve the metallization. Figure 1 is a perspective view of the cathode To this metallizing treatment is due much of and plating tank with the cathode lifted from the credit for the perfection ofthe electroformed the tank.

shells and the rapidity with which the plating Figure 2 is a vertical section through the censo may be started. ter of the tank.

The use of a contact ring which clamps against Figure 3 is a top plan view of tank and filter the inner edge of the matrix throughout its entire equipment with the cathodes in the tank. circumference is another important feature of -Figure 4 is a perspective of the mold frame novelty. By this means current is supplied to all with the electroformed shell and mounting form portions of the surface of the matrix without subtherein. 55

. ing through the flange and into a bead member 21 imbedded in the lower edge of the matrix The. bolting of the lower edge of the matrix The present invention is concerned particularly with the production of tire molds and the illustration is of a method and apparatus for that purpose. As illustrated the new apparatus comprises a cathode assembly; a plating tank and auxiliary equipment, and a mounting form for mounting the electroformed shell in a. mold frame.

Cathode assembly The cathodeassembly comprises a toroidal matrix H of soft rubber mounted upon a form l2 which is in turn supportedby a horizontal triangular plate l3. The plate I3 is integral with a vertical rod l4 adapted to hang from a hook or other suitable support by an eye l5 at itsuppet end. A plurality of the matrixform assemblies may be suspended upon a single supporting rod provided with the requisite num ber of triangular plates. The drawings, Figures 1 and 2, shows two triangular plates I3,-upon each of which rests a matrix-form assembly.

The form I2 is annular inshape with an outer surface I lshaped to support and slightly stretch the matrix H which has the shape of a.latera1 one half of a tire tread section. Completely covering the form is a coating I2a. of a hard rubher which serves to prevent the form from receiving a coating of the metal to be deposited upon the matrix. At the inner or upper edge of the matrix supporting surface I! is a flat section or surface IS. The matrixoverlying this section of surface is thickened slightly and con-, tains imbedded therein .a bead member H) to prevent that part of the matrix from stretching. The bead 'member is preferably a steel ring plated with brass so that the rubber will readily adhere to it.

Against the portion of matrix overlying the flat surface l8 and containing the bead member IS a flat ring 2| of copper or other conductive metal is bolted by cap screws 22 which extend into the form l2 adjacent the edge of the matrix. The heads of these bolts are advantageously daubed with a non-conducting paste to prevent their becoming plated. The ring makes electrical contactwith the metallized surface throughout substantially the whole circumferbe readily made so long as contact is had over substantially the entire circumference of the matrix.

At the lower or outer edge of the matrix supporting surface of the form I2, is a radially extending flange 25 against which the lower edge of the matrix'is bolted by cap screws 26 extendagainst the radial'flange provides the necessary stretching of the matrix to compensate for the .with graphite or graphite and iodine.

shrinkage which takes place in the vulcanization of the matrix. Like the upper bead member, this bead member is also a brass plated steel ring to which the rubber matrix will readily adhere.

Except for the two bead members which are of metal, the matrix is of soft rubber without carbon black and with a minimum of metal salts, preferably of the following formula although other formulas may be substituted.

- Parts by weight Smoked sheet rubber Zinc oxide 50 Sulphur 4 Mercaptobenzotaiazole 0.5 Stearic acid 1 Pine tar 1.5

Three lugs 28 spaced one third 'of the circumference apart around the inside of the annular Me tallization of the matrix After-the c'athod'e has been assembled but before the contact ring 2| has been bolted in place, the surface of the matrix is treated to make it conductive. process of metallization, highly effective wherever metallization is necessary and particularly useful in connection with the present method.

The treatment preferably comprises carefully spraying the surface with a bronze or copper lacquer and then, when dry, dipping the cathode into an alkaline silver cyanide solution. After dipping the silver cyanide solution is immediately rinsed from the-matrix, usually by a light pressure spray. In metallizing a tire matrix it has been sometimes found desirable to cover a strip I I a of the lower edge of the matrix so that this strip will not be metallized and hence not plated.

A satisfactory lacquer may be composed of the following ingredients:

The nitrocellulose lacquer may be of the kind commercially known as Zapon and instead of amyl acetate No. 22 Zapon thinner may be used.

For this purpose there is used a new- They are productsof the Zapon Company of New York city. Aurum K. Lacquer, made by the Zapon Company and having approximately the above formula, may be used. The copper-bronze 5 powder used was made by Baer Bros., and known commercially as Barbour copper-bronze.

The silver cyanide solution may contain 3 ounces of silver cyanide and 6 ounces of sodium cyanide to a gallon of water. However, the exact composition is not essential. When more than one shell is to be formed on a matrix the matrix is preferably remetallized between depositions.

Any kind of metallized cathodes prepared as described or with variations which may easily suggest themselves are highly satisfactory since they permit the plating process to be started rapidly and greatly lessen the danger of imperfections in the deposit.

A possible variation in the process of forming the cathode consists in metallizing the matrix with molten tin projected onto the surface by an air blast after being melted by an acetylene torch. Another variation comprises coating the matrix Plating tank Treatment of the cathode after assembly and metalllzation takes place in a plating tank approximately 5 feet in diameter. The tank itself 35 is in the form of a vertical cylinder the depth-of which depends upon the number of cathodes to be plated simultaneously. For plating two cathodes at a time a depth of 18 inches is suiiicient. Usually the tank is of steel and preferably it is lined with rubber 36. Before use it may be washed out with an acid and with an alkali to remove any materials which might disturb the plating.

Angle members 31 afllxed by bolts 38 to the up-' per edge of the tank support insulating blocks 39 of hard rubber or other insulating material, which in turn support a heavy conductor ring from which hang a number of nickel anodes 4|, spaced about eight inches from the cathode. A source of plating current is connected to the conductor ring by any suitable means.

The anodes are preferably of rolled annealed nickel but'may be of any otherof the usual types such as electronized, cast, or electrolytic. Die cast electrodes deoxldized with magnesium are quite satisfactory. Each anodeis enclosed in a bag 43 of muslin, felt, or other porous material which will allow substantially free circulation of the plating liquid while filtering 'out all solid impurities. When a cloth bag is used it is first washed to remove the starch, sizing and the like. As a substitute a porous clay diaphragm may surround the anodes. While this is even more satisfactory than cloth bags it is also more expensive.

' In the center of the plating tank a large bag 44, of material similar to that of the anode bags, is suspended by straps 45, from the insulating block 39. This bag surrounds the cathode and acts as an additional protection against solid impurities which might cause defects in the plating. The freshly filtered solution is run into this bag from which it filters constantly into the anode section, thus keeping freshsolution always around the cathode.

A final precautionary device against solid impurities consists in a clay cup filter device 48 (Figure 3) through which the plating liquid is continuously forced by a pump 41 during the plating-process. Before plating the entire solution is carefully filtered at a temperature of 120 to The plating solution As more particularly described in the applications of Fred K. Bezzenberger and Ralph C. Batea man already noted, the composition of the bath which it has been found advantageous to use for plating according to the present invention is much different from the usual nickel plating solutions. The ordinary nickel plating baths may, however, be used without departing from the broad scope of this invention. I a

The first major difference in the new bath is in the concentration of nickel which is approximately twice that heretofore used. Instead ofthis change producing an unusable bath as might be expected, it produces a bath of not only greater plating capacity but also of greater throwing power than any of the baths heretofore known.

Thus while a bath of the composition,

Hydrogen peroxide over .10 gram per liter. Specific gravity 1.188 at 60? F.

will operate satisfactorily at no greater rate than 150 amperes per square foot, a bath of the new composition,

Nickel sulphate (memo) oz 80 Nickel chloride (6Hz0) oz 4 Boric acid.. oz 4 Water..- allon 1 Hydrogen peroxide over .10 gram per liter. Specific gravity 1.275 at 78 F.

plates well at 240 amperes per square foot. Furthermore the thickness of the metal deposited in the grooves of a matrix formed as heretofore described is increased approximately 25 per cent by the use of the new bath composition.

Other plating solution formulas employing other salts than nickel sulphate may be used and the exact amounts of the ingredients are not invariable.

Another improvement in the plating bath lies in the control of the acidity. The concentration of the'bath presents a new benefit in this connection since the acidity of the concentrated bath is decidedly more stable and small changes therein have less effect upon the plating. In controlling the acidity it has been found that a pH of 4.8 is

most satisfactory while a bath having a hydrogen oxide is added to and kept in the solution in a such as current density, volta'ge, bath composition and temperature, the amount necessary should be redetermined experimentally should any of these factors be materially changed.

To control the amount of hydrogen peroxide it is first necessary to determine the amount present as the amount consumed varies widely with the conditions'of the plating solution. A reagent for this purpose may be made by adding a solution of .02 gram of cornstarch in 100 cc. of water to a cold solution of 15 grams of potassium iodide in 200 cc. of water. When 5 cubic centimeters of this reagent are added to 10 cubic centimeters of the plating solution a coloration is produced the intensity of which is proportional to the amount of hydrogen peroxide present. In the concentrated plating solution a light coloration is produced by .10 gram per liter of anhydrous hydrogen peroxide while a rather deep color is produced by .60 gram per liter.

The exact amount of peroxide may be determined by comparing the test samples with a standard to which a lmown amount of hydrogen peroxide has been added. However, a little experience enables the operator to judge the amount quite accurately without a standard. Likethe test of acidity, this test is also performed at approximately half hour intervals. The necessary addition of hydrogen peroxide may be made at the time of the test but ispreferably made more slow- 1y by allowing the, hydrogen peroxide to drip into the tank over a considerable period of time. The peroxide may be allowed to drip into the bath continually at a rate which is adjusted according to the'results of the half hour tests.

As a special precaution against foreign matter in-the plating solution it has been found advantageous to filter the solution carefully at a temperature of 120 to 140 F. before it is used.

Process of plating Y osition the filter pump provides the only agitation.

At the start of the plating, which should follow quickly after the cathode is lowered into place, a

low potential is placed across the cell, using either the new concentrated bath or a bath of the concentration usually employed. The voltage is raised slowly during the first fifteen or twenty minutes and then a little faster until the final voltage is attained. For example, using the new concentrated bath, maintained at a. temperature of 120 to 140 F., a potential of two volts may be used to start, andthis may be raised one volt each five minutes for the first fifteen or twenty minutes and then somewhat faster so that at the end of a half hour the voltage is 12 or 13, anda voltage of 18 (which may be used during the balance of the plating operation, is reached in somewhat less than one hour after starting- Whilenot invariable this represents a satisfactory starting period, producing a smooth, closely knit base upon which to form the remainder of the shell.

With the new concentrated bath, after starting, the plating is continued at a. current rate of 150 to 250 amperes per square foot or more thus completing the formation of the shell in 6 to 15 hours or less, with a total deposit of from 800 to 4000 ampere hours per square foot of cathode surface.

Surprising as it may seem, the metal so rapidly deposited is not burned but is especially ductile and smooth, both within the grooves and on the outer surfaces of the tread. Furthermore, the

relative thickness of the metal within the deep grooves of the matrixmay be increased by 25 percent or more due to increased throwing power resulting from the new process.

During the deposition it has been found advantageous to lift the cathode from the solution occasionally tofree it from bubbles'entrapped in the grooves or clinging to the surfaces. This lifting is conveniently done every half hour but may be done less often or eliminated entirely if careis taken to be sure that the cathode is thoroughly wet at the beginning of the plating. At the end of the plating the cathode is carefully rinsed, the matrix and shell removed and stripped zontally on a suitable support, with the large circumference resting on the support, and then push the matrix down thru an opening support and away from the shell.

Mold from ring 50, one of the lateral surfaces of which is hollowed out to form half of a mold for a vehicle tire. A circumferentially extending section inthe 5|, of the surface of the hollowed out portion is I cut accurately to the shape which is to be given to the side wall of the tire, while the remaining section 52 of the surface is merely cut away to receive and support the electroformed shell 4! which is to shape the tread portion. The section 52 which is to support the electroformed shell is preferably, although not necessarily, formed with dove-tail grooves 53 therein. The grooves permit the metal which seals the shell to the frame to anchor itself firmly ,to theframe. Two lugs 54 projecting inwardly from the annular frame and pierced by openings 55 provide means for handling the mold with the hook of a lift.

' Mounting the shell' The electroformed shell includes, at both the inner and outer diameters, an extension which forms no part of the mold itself, but is useful in assembling the shell in the mold frame. The upper extension 80 serves to anchor theshell into the frame, and the. lip 84 affords an appendage easily graspednmd useful in drawing the shell into position in the mold frame, as explained below. It is not necessary that either of these extensions encircle the entire shell,as suitable extensions at more or less frequent intervals may be used.

To mount the shell I9 in the mold frame, the shell which may be bent somewhat in stripping or must be brought back to the desired shape. This is effected by the use of a. solid metalring or jig 60 of a shape similar to a lateral one half of a tire, thus having a curved side 6| against which the shell 49 is pressed to shape it, and a flat side 62. On the flat side adjacent the outer edge are a. plurality of holes 63 each adapted to receive the unthreaded end of a bolt 54 threaded through the body member 55 of a small clamp. A wing head 66 on the bolt permits manual removal'thereof fromthe clamp.

In mounting the shell 49 in the mold frame the p jig is first removed from the frame, then the shell is placed in the frame with the anchor ring 80 placed against the circular ring 0| of the frame. The shell 49 may be bent somewhat in handling and it is necessary that it be properly lined up before the molten metal used to back it up is poured into place. To line the shell'up the jig 60 is inserted in the frame with the'surface' 82 of the jig registering against the surface 83 of the frame. By tightening the nuts 81 on the hook shaped bolts 13 which are hooked through the openings 55 in the lugs 54 on the mold the bar 12 holds the jig firmly in place. With the jig thus in place it is important to draw the shell up around the jig and this is done by pulling on the lip CI of" the shell. When the shell is pulled up so that the surface 85 registers against the. surface 86 of the jig the lip 04 is clamped in place by turning the set screws II so as to push'the upper ends 69 of the clamping fingers away from the body of the clamps and thus cause'the lower ends 58 to hold thelip-ll firmly in'place. m molten metal 'has set and the bar 12 and ring 14 have been removed, this excess metal is machined of! to the height of the surface 86 and the lip 84 of the shell is trimmed so that the shell and the molten metal as well as the surface of the mold are periectly even at this point, and will register perfectly with another mold and shell similarly formed so that when the two are placed together a tight mold is obtained. Eyes I I on the jig provide means for readily grasping it with the book of a hoist.

A soft metal which may be advantageously used to attach the shell to the frame comprises parts of lead, 18 parts of antimony, 20 parts of tin, ,1 part of copper and 1 part of bismuth.

Other compositions such as parts lead, 19

parts antimony, 5 parts tinand 1 part copper are also satisfactory.

I claim: i

1. In forming a tire mold from an electrodeposited shell for the tread portion thereof and a mold frame which includes in addition to a surface to form the side wall, a cavity for the shell,

' the steps which comprise placing the shell so that one portion thereof is adjacent the side-wall surface in the frame, then bringing the shell into the position necessary to form the tire mold by space between the mold and shell.

2. In forming a tire mold froman electrodeposited shell for the tread portion thereof and a mold frame which includes in addition to a surface to form the side wall, a cavity for the shell, the boundary between said surface and cavity being circular and the shell being formed with a circular appendage to fit thereover, the steps which comprise placing the shell with said appendage in place on said frame, and holding it in place by means of a jig, pulling the shell up tightly against the jig and then permanently securing the shell in place by pouring molten metal between the shell and the wall of said cavity and allowing the metal to harden.

3. Apparatus for forming a tire mold that comprises a metallized rubber matrix cathode, a plating bath, means to support the matrix horizontally in the bath, means to supply electric current uniformly to the entire surface of the matrix and ,the shell in place, and means anchored tothe inner wall of the annulus for holding the jig in place.

RALPH C. BATEMAN. 

